Yamaha F40b Outboard Service Repair Manual Pid Range 67c 1035037 1044888 Mfg Aprill 2005 And Newer -

F40B

SERVICE MANUAL *LIT186160304* LIT-18616-03-04

67C-28197-1K-11

NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.

Important information

1

Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE: A NOTE provides key information to make procedures easier or clearer.

F40B SERVICE MANUAL Š2007 by Yamaha Motor Corporation, USA 1st Edition, August 2007 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited.

Printed in USA LIT-18616-03-04

Contents General information Specification Periodic check and adjustment Fuel system Power unit Lower unit Bracket unit

GEN INFO

SPEC

CHK ADJ

FUEL

POWR

LOWR

BRKT –

Electrical system Troubleshooting Index

+

ELEC

TRBL SHTG

1 2 3 4 5 6 7 8 9

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GEN INFO

General information How to use this manual ................................................................................. 1-1 Manual format............................................................................................ 1-1 Symbol....................................................................................................... 1-2 Abbreviation............................................................................................... 1-3 Sealant and locking agent table ................................................................ 1-3 Safety while working...................................................................................... 1-4 Fire prevention........................................................................................... 1-4 Ventilation.................................................................................................. 1-4 Self-protection ........................................................................................... 1-4 Part, lubricant, and sealant........................................................................ 1-4 Good working practice............................................................................... 1-5 Disassembling and assembling ................................................................. 1-5 Identification................................................................................................... 1-6 Model......................................................................................................... 1-6 Serial number ............................................................................................ 1-6 Special service tool ....................................................................................... 1-7 Propeller selection ....................................................................................... 1-12 Propeller size........................................................................................... 1-12 Selection.................................................................................................. 1-12 Predelivery check ........................................................................................ 1-13 Checking the outboard motor mounting height........................................ 1-13 Checking the fuel system ........................................................................ 1-13 Checking the engine oil level................................................................... 1-13 Checking the gear oil level ...................................................................... 1-14 Checking the battery (E model) ............................................................... 1-14 Connecting the throttle cable and shift cable........................................... 1-14 Checking the gear shift and throttle operation......................................... 1-15 Checking the steering system ................................................................. 1-16 Checking the tilt system (D model).......................................................... 1-16 Checking the PTT system (PTT model) .................................................. 1-17 Checking the engine start switch and engine shut-off switch .................. 1-17 Checking the cooling water pilot hole ...................................................... 1-18 Test run ................................................................................................... 1-18 Break-in ................................................................................................... 1-19 After the test run ...................................................................................... 1-19 Precaution when transporting or storing the outboard motor .................. 1-19

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1 2 3 4 5 6 7 8 9

GEN INFO

General information

How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service.

• Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1 in the figure below for an example page).

• The component list consists of part names and quantities, as well as bolt and screw dimensions (see 2 in the figure below).

• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point (see 3 in the figure below).

• Tightening torque specifications are provided in the exploded diagrams (see 4 in the figure below for an example), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees.

• Separate procedures and illustrations are used to explain the details of removal, checking, and installation where necessary (see 5 in the figure below for an example page).

NOTE: For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

4

1

3

2 5

1-1

67C1K11

How to use this manual

Symbol The symbols below are designed to indicate the content of a chapter.

General information

Fuel system

GEN INFO

Bracket unit

FUEL

Specification

BRKT

Power unit

SPEC

Electrical system

POWR

Periodic check and adjustment

CHK ADJ

–

ELEC

Lower unit

+

Troubleshooting

TRBL SHTG

LOWR

Symbols 1 to 6 indicate specific data.

1

2

3

4

5

6

T.

R.

1 2 3 4

5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current)

Special service tool Specified oil or fluid Specified engine speed Specified tightening torque

Symbols 7 to C in an exploded diagram or illustration indicate the grade of lubricant and the lubrication point.

7

8

9

0 A

E 7 8 9 0

A M

B

C

D

C

I

G

Apply 4-stroke motor oil Apply gear oil Apply water resistant grease (Yamaha grease A) Apply molybdenum disulfide grease

A Apply corrosion resistant grease (Yamaha grease D) B Apply low temperature resistant grease (Yamaha grease C) C Apply injector grease

Symbols D to I in an exploded diagram or illustration indicate the type of sealant or locking agent and the application point.

D

E GM

F 1104J

D Apply Gasket Maker E Apply ThreeBond 1104J F Apply LOCTITE 271 (red)

67C1K11

G

H

I

LT

LT

LT

271

242

572

SS

G Apply LOCTITE 242 (blue) H Apply LOCTITE 572 I Apply silicone sealant

1-2

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Abbreviation The following abbreviations are used in this service manual.

Abbreviation

Description

ABYC

American Boat and Yacht Council

API

American Petroleum Institute

ATDC

After Top Dead Center

BOW

Bow end

CCA

Cold Cranking Ampere

CDI

Capacitor Discharge Ignition

D model

Hydraulic tilt model

E model

Electric starter model

EX

Exhaust

F position

Forward position

H model

Tiller handle model

IN

Intake

M model

Manual starter model

MCA

Marine Cranking Ampere

N position

Neutral position

PORT

Port side

PTT

Power trim and tilt

R model

Remote control model

R position

Reverse position

RC

Reserve Capacity

SAE

Society of Automotive Engineers

STBD

Starboard side

WD

Wiring Diagram

Sealant and locking agent table The following table contains sealants, locking agents, and lubricants used in this service manual that are not listed on page 1-2.

Symbol 518

1-3

Name

Application

Manufacturer

LOCTITE 518

Sealant

Henkel

67C1K11

How to use this manual / Safety while working

Safety while working To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below.

Fire prevention Gasoline is highly flammable.

Keep gasoline and all flammable products away from heat, sparks, and open flames.

Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the outboard motor.

Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities, they may cause loss of consciousness and death within a short time.

When test running an engine indoors (e.g., in a water tank), be sure to do so where adequate ventilation can be maintained.

Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants.

1. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket.

Self-protection Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor.

Protect your hands and feet by wearing protective gloves and safety shoes when necessary.

2. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made.

3. Change and wash clothing as soon as possible if soiled with lubricants.

4. To protect your skin, apply a protective cream to your hands before working on the outboard motor.

5. Keep a supply of clean, lint-free cloths for wiping up spills, etc.

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1-4

1 2 3 4 5 6 7 8 9

GEN INFO

General information

6. Maintain good standards of personal and industrial hygiene.

Disassembling and assembling 1. Use compressed air to remove dust and dirt during disassembly.

Good working practice Special service tool Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise.

Tightening torque Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward.

Non-reusable part Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or assembling parts.

1-5

2. Apply oil or fluid to the contact surfaces of moving parts before assembly.

3. Install bearings with the manufacture identification mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally.

4. Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation.

5. Check that moving parts operate normally after assembly.

67C1K11

Safety while working / Identification

Identification Model This manual covers the following models.

1 2 3 4 5 6 7 8 9

Applicable model F40BMH, F40BTR

Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket.

S67C1010

1 2 3 4

Model name Approved model code Transom height Serial number

Model name

Approved model code

Starting serial No.

F40B

67C

1035037–

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1-6

GEN INFO

General information

Special service tool

Oil filter wrench YU-38411

Compression gauge YU-33223

Digital tachometer YU-39951-B

Flywheel holder YB-06139

Timing light YU-03141

Universal puller YB-06117

Pressure/vacuum tester YB-35956-A

Valve spring compressor YM-04019

Vacuum mate carb sync gauge YU-44456

Valve attachment YB-06320

1-7

67C1K11

Special service tool

Valve guide remover YB-06801

Piston ring compressor YM-08037

Valve guide reamer YM-01196

Slide hammer YB-06096

Neway valve seat kit YB-91044

Bearing puller legs YB-06523

Driver handle (large) YB-06071

Bearing housing bearing/oil seal remover YB-06112

Bearing/oil seal depth plate YB-06110

Bearing housing bearing/installer YB-06111

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1-8

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Oil seal installer YB-06168

Roller bearing installer/remover YB-06432

Reverse/forward gear bearing installer YB-06276-B

Drive shaft needle bearing remover/ installer YB-06063

Bearing cup installer YB-06167

Drive shaft holder YB-06079

Bearing splitter plate YB-06219

1-9

Forward gear outer race installer YB-41446

Forward gear bearing installer YB-06270-A

Bearing installer-reverse gear bearing YB-06016

67C1K11

Special service tool

Pinion shim selecting tools YB-34432-8, YB-34432-10, YB-34432-11, YB-34432-17,

Forward gear shim selecting tools YB-34446-1, YB-34446-3, YB-34446-5, YB-34446-7

1 2 3 4 5 6 7 8 9

Backlash indicator rod YB-06265

Backlash adjustment plate YB-07003

Dial indicator gauge YU-03097 Digital vernier calipers YU-A5400

Magnetic base stand YU-A8438 Shimming plate 90890-06701

Reverse gear bearing remover YB-41707 Bearing housing puller YB-06207

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1-10

GEN INFO

General information

Pinion gear bushing installer YB-06029-4

PTT cylinder wrench YB-06175-2B

Driver handle (small) YB-06229

Peak volt adapter YU-39991

Crankshaft seal installer YB-06349

Test harness (2 pins) YB-06867

Digital multimeter YU-34899-A

Spark checker YM-34487

Bearing housing/drive shaft bearing remover/installer YB-06082

Test harness (2 pins) YB-06868

1-11

67C1K11

Special service tool / Propeller selection

Propeller selection The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also seriously damage the engine.

Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor.

×

a

-

b c S69W1050

a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark)

Selection Propeller size The size of the propeller is indicated on a propeller blade, on the propeller boss end, and on the side of the propeller boss.

When the engine speed is in the full throttle operating range (5,000–6,000 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption.

Propeller size (in)

×

a

Material

10 × 15 - G

-

10 1/4 × 14 - G*

b c

10 1/4 × 15 - G 10 1/4 × 16 - G 10 3/8 × 13 - G S69W1040

10 5/8 × 12 - G 10 5/8 × 13 - G 10 3/4 × 16 - G

×

a

-

10 3/4 × 17 - G

b c

11 1/8 × 13 - G

Aluminum

11 1/4 × 14 - G* 11 3/8 × 12 - G* 11 1/2 × 13 - G S69W1030

11 5/8 × 11 - G 11 3/4 × 12 - G 12 × 11 - G 12 1/4 × 9 - G *: This propeller is available in 2 types.

67C1K11

1-12

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Predelivery check To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below.

Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is between the bottom of the boat and a maximum of 25 mm (1 in) a below it. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency.

S67C1016

CAUTION: This is a 4-stroke engine. Never use premixed fuel or 2-stroke outboard motor oil.

Checking the engine oil level

a

1. Check the engine oil level.

S6D51030

NOTE: The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at different heights.

b

a S67C1017

2. Check that the clamp brackets are secured with the clamp bolts.

Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.

1-13

NOTE: If the engine oil is below the minimum level mark a, add sufficient oil until the level is between a and b.

Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, SJ, or SL SAE: 5W-30, 10W-30, or 10W-40 Engine oil quantity: Without oil filter replacement: 2.0 L (2.11 US qt, 1.76 Imp qt)

67C1K11

Predelivery check 2. Turn the throttle cam 1 clockwise until the cam contacts the fully closed stopper a on the throttle cam bracket 2 and hold it in that position. Connect the throttle cable 3 to the throttle cam, and then install the clip 4.

Checking the gear oil level 1. Check the gear oil level.

4 1

3

S67C1019

NOTE: If the oil is at the correct level, a small amount of oil should overflow out of the check hole when the gear oil check screw is removed.

a 2

S67C1020

Checking the battery (E model) 1. Check the battery capacity, electrolyte level, and specific gravity of the electrolyte.

Recommended battery capacity: CCA/SAE: 380 A MCA/ABYC: 502 A RC/SAE: 124 minutes Electrolyte specific gravity: 1.280 at 20 °C (68 °F) 2. Check that the positive and negative battery cables are securely connected.

Connecting the throttle cable and shift cable NOTE: To adjust the throttle cable and shift cable, see “Adjusting the throttle cable” (3-8) or “Checking the gear shift operation” (3-9).

1. Set the shift lever or remote control lever to the N position and the throttle grip or throttle lever to the fully closed position.

67C1K11

1-14

1 2 3 4 5 6 7 8 9

GEN INFO

General information

3. Check that the shift arm 5 is in the N position as shown. Connect the shift cable 6 to the shift arm, and then install the clip 7.

È

7 N

R

d

6 F

2. Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from the N position to the F position or R position.

5

N F

c

R

a 1

S67C1021

É

S67C1024

N F

R a

a

b S67C1047

WARNING The shift/throttle cable joint must be screwed in a minimum depth of 8.0 mm (0.31 in) b.

NOTE: Center the shift arm 5 in its free play c and the shift cable 6 in its free play d, and then connect the shift cable.

Checking the gear shift and throttle operation 1. Check that the throttle operates smoothly when the throttle grip is turned from the fully closed position to the fully open position a. (H model) Check that the throttle operates smoothly when the remote control lever is shifted from the F position or R position to the fully open position a. (R model)

1-15

1

S6AU1024

È H model É R model

NOTE: • The shift lever cannot be operated unless the throttle grip is in the fully closed position. (H model) • The resistance of the throttle grip (H model) or remote control lever (R model) can be adjusted using the throttle friction adjuster 1.

3. Set the shift lever to the F position or R position, and then check that the starter handle cannot be pulled. If the starter rope can be pulled out normally, adjust the start-in-gear protection cable. (M model)

67C1K11

Predelivery check É

N

R

F

S67C1027

NOTE: To adjust the start-in-gear protection cable, see “Checking the start-in-gear protection (M model)” (3-10).

S67C1030

È H model É R model

3. Check that there is no interference with leads, cables, or hoses when the outboard motor is steered.

Checking the steering system

Checking the tilt system (D model)

1. Check the steering friction for proper adjustment. (H model)

1. Set the tilt lock lever 1 to the release position a and tilt the outboard motor to the fully up position. Check that the outboard motor tilts up smoothly.

a b a S67C1028

NOTE: • To increase the friction, move the steering lock lever in direction a.

• To decrease the friction, move the steering lock lever in direction b.

2. Check that smoothly.

the

steering

1 S67C1031

2. Set the tilt lock lever 1 to the lock position b and check that the outboard motor is locked in the tilted-up position.

operates

È

1 b

S67C1029

67C1K11

S67C1033

3. Check that there is no interference with leads, cables, or hoses when steering the motor in its fully up position.

1-16

1 2 3 4 5 6 7 8 9

GEN INFO

General information

4. Set the tilt lock lever 1 to the release position a and tilt the outboard motor to the fully down position. Check that the outboard motor tilts down smoothly.

È

Checking the PTT system (PTT model) 1. Check that the outboard motor tilts up and down smoothly when operating the PTT switch.

S67C1038U

É UP

DN

S6AU1035

S67C1035

2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down.

3. Check that there is no interference with leads, cables, or hoses when steering the motor in its fully up position.

È H model É R model

3. Check that the engine turns off when the clip is pulled from the engine shut-off switch. È

Checking the engine start switch and engine shut-off switch 1. Check that the engine starts when the engine start switch is turned to “START.” S67C1042U

É

S6AU1035

2. Check that the engine turns off when the engine shut-off switch is pushed. (H model) Check that the engine turns off when the engine start switch is turned to “OFF.” (R model)

1-17

È H model É R model

67C1K11

Predelivery check

Checking the cooling water pilot hole 1. Place the lower unit in water, and then start the engine.

NOTE: The test run is part of the break-in operation.

1 2 3 4 5 6 7 8 9

2. Check for water flow at the cooling water pilot hole.

1

S67C1044

NOTE: Make sure that the cooling water hoses are securely connected and that the flushing hose joint adapter 1 is not loose or damaged.

Test run 1. Start the engine, and then check that the gear shift operates smoothly.

2. Check the engine idle speed after the engine has been warmed up.

3. Operate at trolling speed.

4. Run the outboard motor for 1 hour at varying speeds up to 2,000 r/min or approximately half throttle, then, for another hour, increase engine speed as much as necessary to put the boat on plane (but avoid full-throttle operation).

5. Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom.

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1-18

GEN INFO

General information

Break-in Run the engine under load (in gear with a propeller installed) for 10 hours as follows.

1. For the 1st hour a of operation: Run the engine at varying speeds up to 2,000 r/min or approximately half throttle.

2. For the 2nd hour b of operation: Increase engine speed as much as necessary to put the boat on plane (but avoid full-throttle operation), then back off on the throttle while keeping the boat at a planing speed.

NOTE: When using the flushing device (flushing hose joint adapter), flush the cooling water passages without starting the engine.

Precaution when transporting or storing the outboard motor 1. When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown or use an outboard motor stand.

3. For the remaining 8 hours c of operation: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.

4. After the 1st 10 hours of operation: Operate the engine normally.

a Ăˆ 0

b

1

S67C1048

c

2

10

S69J1240

Ăˆ Hour

After the test run 1. Check for water in the gear oil.

2. Check for fuel leakage in the cowling.

3. Flush the cooling water passages with fresh water using the flushing kit and with the engine running at idle.

CAUTION: Be sure to supply sufficient water and water pressure when flushing the cooling water passages. If sufficient water and sufficient water pressure are not supplied, the engine can overheat.

1-19

67C1K11

SPEC

Specification General specification..................................................................................... 2-1 Maintenance specification ............................................................................ 2-3 Power unit.................................................................................................. 2-3 Fuel system ............................................................................................... 2-7 Lower unit .................................................................................................. 2-7 Electrical .................................................................................................... 2-8 Dimension................................................................................................ 2-11 Tightening torque......................................................................................... 2-14 Specified torque....................................................................................... 2-14 General torque......................................................................................... 2-16

67C1K11

1 2 3 4 5 6 7 8 9

SPEC

Specification

General specification Item Dimension Overall length Overall width Overall height (L) Transom height (L) Boat transom height (L) Weight (with aluminum propeller) (L) Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed Power unit Type Cylinder quantity Total displacement Bore × stroke Compression ratio Control system Starting system Fuel system Enrichment system Ignition control system Advanced type Ignition timing at 850 r/min Maximum generator output Spark plug Cooling system Exhaust system Lubrication system

2-1

Unit

Model F40BMH

mm (in) mm (in)

1,332 (52.4)

mm (in)

1,369 (53.9)

F40BTR 700 (27.6) 378 (14.9) 1,340 (52.8)

mm (in)

533 (21.0)

mm (in)

508 (20.0)

kg (lb) kW (HP) r/min L (US gal, Imp gal)/hr r/min

cm3 (cu. in) mm (in)

Degree W, A V, A

88.1 (194)

90.4 (199)

29.4 (40) at 5,500 r/min 5,000–6,000 15.0 (4.0, 3.3) at 6,000 r/min 850 ± 50 4-stroke L 3 747 (45.6) 65.0 × 75.0 (2.56 × 2.95) 9.87 Tiller handle Remote control Manual Electric Carburetor Prime Start CDI (micro computer) Micro computer ATDC 5 ± 2 85, 6.0 — — 12, 15.0 DPR6EA-9 (NGK) Water Propeller boss Wet sump

67C1K11

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL